Sequencing of multi-pass laser shock peening applications

ABSTRACT

A method for laser shock peening (LSP) a workpiece is disclosed. The method may include identifying a geometry of the workpiece, determining a number of applications of LSP upon a first side and a second side of the workpiece, and sequencing the applications among the first side and the second side to minimize distortion.

CROSS-REFERENCE TO RELATED APPLICATION

This patent application is a US National Stage under 35 U.S.C. §371,claiming priority to International Application No. PCT/US13/76076 filedon Dec. 18, 2013, which claims priority under 35 U.S.C. §119(e) to U.S.Patent Application Ser. No. 61/798,474 filed on Mar. 15, 2013.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to gas turbine engines and,more particularly, to a method for laser shock peening parts of a gasturbine engine.

BACKGROUND OF THE DISCLOSURE

Gas turbine engines may typically include a compressor, a combustor, anda turbine, with an annular flow path extending axially through each.Initially, air flows through the compressor where it is compressed orpressurized. The combustor then mixes and ignites the compressed airwith fuel, generating hot combustion gases. These hot combustion gasesare then directed from the combustor to the turbine where power isextracted from the hot gases by causing blades of the turbine to rotate.

Various parts of the gas turbine engine, such as compressor or turbinerotor blades, are susceptible to cracking from stress, fatigue anddamage (e.g. foreign object debris). This damage can reduce the life ofthe part, requiring repair or replacement. To protect parts from crackinitiation and propagation, residual compressive stresses can beimparted into the part by a material improvement process, such as shotpeening, laser shock peening (LSP), pinch peening, and low plasticityburnishing (LPB). However, current application techniques of materialimprovement processes alter the profile or geometry of the part. Forexample, when an airfoil is treated with LSP, there is a distortion intwist and/or lean of the airfoil. Accordingly, there exists a need for amethod to minimize the distortion in parts due to material improvementprocesses. This invention is directed to solving this need and others.

SUMMARY OF THE DISCLOSURE

According to one exemplary embodiment of the present disclosure, amethod for laser shock peening (LSP) a workpiece is disclosed. Themethod may comprise identifying a geometry of the workpiece, determininga number of applications of LSP upon a first side and a second side ofthe workpiece, and sequencing the applications among the first side andthe second side to minimize distortion.

In a refinement, the method may further comprise providing oneapplication to the first side of the workpiece, and measuring a changein geometry of the workpiece.

In another refinement, the method may further comprise providing oneapplication to the second side of the workpiece, and measuring a changein geometry of the workpiece.

In another refinement, the method may further comprise determining whichside of the workpiece to apply a first application of LSP.

In another refinement, the method may further comprise determining asequence of the applications based on measured changes in geometry ofthe workpiece after each successive application.

In another refinement, the method may further comprise using acoordinate measuring machine (CMM) to measure the geometry of theworkpiece.

According to another exemplary embodiment of the present disclosure, amethod for working an airfoil is disclosed. The method may compriseidentifying an initial geometry of the airfoil, determining a number ofapplications of LSP upon each of a first side and a second side of theairfoil, and providing the applications in a sequence having a minimumamount of variation from the initial geometry of the airfoil.

In another refinement, the method may further comprise providing threeapplications to each of the first side and the second side of theairfoil.

In a refinement, the method may further comprise determining thesequence based on an amount of variation from the initial geometry ofthe airfoil after each application.

In another refinement, the method may further comprise providing thesequence as a first application to the first side, a second applicationto the second side, a third application to the second side, a fourthapplication to the first side, a fifth application to the first side,and a sixth application to the second side.

According to yet another exemplary embodiment of the present disclosure,a method for manufacturing an airfoil of a gas turbine engine isdisclosed. The method may comprise measuring an initial geometry of theairfoil, determining a number of applications of laser shock peening toprovide on the airfoil, determining a sequence for the applications,determining a new geometry for the airfoil based on the initial geometryand the sequence, providing an airfoil according to the new geometry,and applying the sequence on the airfoil having the new geometry.

In a refinement, the method may further comprise measuring the initialgeometry of the airfoil, including at least one of thickness, chordlength, camber, twist, and lean.

In another refinement, the method may further comprise applying a firstapplication to a pressure side of the airfoil.

In another refinement, the method may further comprise providing asecond application to a suction side, a third application to the suctionside, a fourth application to the pressure side, a fifth application tothe pressure side, and a sixth application to the suction side.

In another refinement, the method may further comprise providingapplications to the pressure and suction sides of the airfoil andmeasuring variations in geometry to determine the sequence.

In another refinement, the method may further comprise determining thesequence based on a sequence having a smallest amount of variation ingeometry.

In another refinement, the method may further comprise applying thesequence to an airfoil having the initial geometry.

In another refinement, the method may further comprise measuring anamount of variation in geometry from the initial geometry after applyingthe sequence.

In another refinement, the method may further comprise designing the newgeometry of the airfoil to compensate for the measured amount ofvariation in geometry.

In yet another refinement, the method may further comprise compensatingfor the measured amount of variation in geometry by offsetting a leanand a twist in the new geometry of the airfoil.

These and other aspects and features of the disclosure will become morereadily apparent upon reading the following detailed description whentaken in conjunction with the accompanying drawings. Although variousfeatures are disclosed in relation to specific exemplary embodiments ofthe invention, it is understood that the various features may becombined with each other, or used alone, with any of the variousexemplary embodiments of the invention without departing from the scopeof the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a gas turbine engine constructed inaccordance with the present disclosure;

FIG. 2 is a flowchart outlining a method for applying laser shockpeening (LSP) on a workpiece, according to one exemplary embodiment ofthe present disclosure;

FIG. 3 is a perspective view of an airfoil of the gas turbine engine ofFIG. 1;

FIG. 4 is a flowchart outlining a method for determining a sequence forapplication of LSP on an airfoil, according to another exemplaryembodiment of the present disclosure; and

FIG. 5 is a flowchart outlining a method for manufacturing an airfoil ofa gas turbine engine, according to yet another exemplary embodiment ofthe present disclosure.

While the present disclosure is susceptible to various modifications andalternative constructions, certain illustrative embodiments thereof,will be shown and described below in detail. It should be understood,however, that there is no intention to be limited to the specificembodiments disclosed, but on the contrary, the intention is to coverall modifications, alternative constructions, and equivalents fallingwithin the spirit and scope of the present disclosure.

DETAILED DESCRIPTION

Referring now to the drawings, and with specific reference to FIG. 1, inaccordance with the teachings of the disclosure, an exemplary gasturbine engine 20 is shown. The gas turbine engine 20 may generallycomprise a compressor section 22 where air is pressurized, a combustor24 downstream of the compressor section which mixes and ignites thecompressed air with fuel and thereby generates hot combustion gases, aturbine section 26 downstream of the combustor 24 for extracting powerfrom the hot combustion gases, and an annular flow path 28 extendingaxially through each. The gas turbine engine 20 may be used on anaircraft for generating thrust or power, or in land-based operations forgenerating power as well.

To protect components of the gas turbine engine 20 from crack initiationand propagation, components may be treated via laser shock peening(LSP), which imparts residual compressive stresses into the component.Although laser shock peening is described herein, it is to be understoodthat other material improvement processes such as, but not limited to,shot peening, pinch peening, low plasticity burnishing (LPB), or thelike, may be used instead of LSP to treat components without departingfrom the spirit of the disclosure. Referring now to FIG. 2, a flowchartoutlining a method 30 for applying LSP on a workpiece is shown,according to an exemplary embodiment of the present disclosure.

The method 30 may be applied to any component of the gas turbine engine20. For example, the method 30 may be applied to an airfoil 40 of thegas turbine engine 20, such as the one shown in FIG. 3. The airfoil 40may comprise a rotor blade or stator vane in the compressor section 24or turbine section 28 of the gas turbine engine 20. The airfoil 40 maycomprise a first side 42 and an opposite second side 44 projectingradially from a base 45 to a tip 46 and extending axially (fore to aft)from a leading edge 47 to a trailing edge 48 (downstream of the leadingedge 47).

At a first step 32 of the method 30, an original or initial geometry ofthe workpiece may be identified. For example, a coordinate measuringmachine (CMM) may be used to measure the geometry of the workpiece,although other means of measurement are certainly possible. In theexample of the airfoil 40 of FIG. 3, the CMM may be used to measurecertain geometric features of the airfoil 40, such as, but not limitedto, thickness, chord length, camber, twist, and lean.

At a next step 34, a number of applications of LSP to provide on theworkpiece may be determined. One application of LSP may be provided onthe workpiece or more than one application of LSP may be provided on theworkpiece. For example, it may be determined that three applications ofLSP may be provided to the first side 42 of the airfoil 40 and threeapplications of LSP may be provided to the second side 44 of the airfoil40. More or less than three applications of LSP on each of the first andsecond sides 42, 44 are certainly possible.

Next, at a step 36, the applications may be provided in a sequence whichminimizes distortion of the workpiece. After determining the initialgeometry of the workpiece and the amount of applications of LSP, thesequence of applications may be arranged such that the initial geometryof the workpiece is not altered or minimally altered. For example, theapplications may be sequenced among the first and second sides 42, 44 ofthe airfoil 40 such that there is minimal variation from the initialgeometry of the airfoil 40 after providing the applications of LSP.

More specifically, the most beneficial sequence for application of LSPon the workpiece may be determined. For example in FIG. 4, a flowchartoutlining a method 50 for determining the sequence for application ofLSP is shown, according to another exemplary embodiment of the presentdisclosure. At a first step 52, the airfoil is provided, the geometry ofthe airfoil is measured, and the number of applications of LSP isdetermined. Next, at a step 54, either the first side 42 or the secondside 44 of the airfoil is chosen for providing of one application ofLSP. If the first side 42 is chosen, then the application is provided tothe first side 42 of the airfoil 40 at a step 56. If the second side 44is chosen, then the application is provided to the second side 44 of theairfoil 40 at a step 58.

Next, at a step 60, the variation in geometry of the airfoil 40 ismeasured. For example, at least one of a thickness, chord length,camber, twist, and lean may be measured by the CMM after eachapplication to either of the first or second sides 42, 44. The change orvariation in the measured geometric features may be then determined withreference to the initial geometry of the airfoil measured in step 52.

At a subsequent step 62, an order of the sequence of application of LSPon the first and second sides 42, 44 of the airfoil 40 is determined.For example, with regard to a first application of LSP, the firstapplication may be provided to the first side 42 of the airfoil 40 andthe variation in geometry may be measured. Separately, on anotherairfoil having the same geometry, the first application may be providedto the second side 44 of the airfoil 40 and the variation in geometrymay be measured. Comparing the variation in geometry when the firstapplication is provided to the first side 42 with the variation ingeometry when the first application is provided to the second side 44,the side (first 42 or second 44) to provide the first application may bedetermined.

For example, the first and second sides 42, 44 may have differentcontours, with the first side 42 being a pressure side of the airfoil 40and the second side 44 being a suction side of the airfoil 40. Due tothe different shapes of pressure and suction surfaces, the firstapplication on either the pressure side or the suction side may havedifferent effects on the geometry of the airfoil 40. For example,because the pressure side is flatter than the curved suction side, thefirst application upon the pressure side may result in a smallervariation in geometry of the airfoil 40 than the variation in geometryafter the first application upon the suction side. Therefore, it may bedetermined that the first application should be provided to the pressureside or first side 42 of the airfoil 40 as a beginning order of thesequence. It is to be understood the first application may also beprovided on the suction side or second side 44 of the airfoil 40 as thebeginning order of the sequence without departing from the scope of thepresent disclosure.

Next, at a step 64, if the determined number of applications (step 52)are all provided to the airfoil 40 or completed, then the method 50 isat an end. However, if more applications are to be provided to theairfoil 40, then the method proceeds to step 54 and the process isrepeated for the determined number of applications. Based on themeasured changes or variations in geometry of the airfoil 40 after eachsuccessive application, the most beneficial sequence is determined. Forexample, the method 50 may be repeated using different sequences, suchas changing the order of the applications between the first side 42 andthe second side 44 determined at step 54. For each different sequence,after a last application is provided and the variation in geometry ismeasured, the amount of variation in geometry among the differencesequences is compared. A sequence having the minimum amount of variationfrom the initial geometry of the airfoil 40 (or the least amount ofdistortion to the airfoil 40) would then be determined as the mostbeneficial sequence.

In an example of three applications to the first side 42 and threeapplications to the second side 44 (six applications in total), with thefirst side 42 being the pressure side and the second side 44 being thesuction side, the most beneficial sequence may be a first application tothe first side 42, a subsequent second application to the second side44, a subsequent third application to the second side 44, a subsequentfourth application to the first side 42, a subsequent fifth applicationto the first side 42, and a subsequent sixth application to the secondside 44. The most beneficial sequence may result in the least amount ofdistortion to the geometry of the airfoil 40. It is to be understoodthat the described sequence is for exemplary purposes only, and thatother sequences are certainly possible.

It is to be understood that although described as having the minimumamount of variation from the initial geometry of the airfoil (or theleast amount of distortion to the airfoil), the determined sequence mayalso result in no amount of variation from the initial geometry of theairfoil or zero distortion to the airfoil. In addition, determinedsequences may differ from one airfoil to the next depending on thegeometry of the airfoil and/or the number of applications of LSP on theairfoil. These various sequences are positively within the scope of thisdisclosure.

Referring now to FIG. 5, a flowchart outlining a method 70 formanufacturing an airfoil of a gas turbine engine is shown, according toyet another exemplary embodiment of the present disclosure. At a firststep 72, the original or initial geometry of the airfoil 40 may bemeasured, as described above. At a next step 74, the number ofapplication of LSP to upon the airfoil 40 may be determined. Next, at astep 76, the sequence for the applications may be determined, such as,via method 50 in FIG. 4 described above.

At a next step 78, a new geometry for the airfoil 40 may be determinedbased on the initial geometry of the airfoil from step 72 and thedetermined sequence from step 76. More specifically, the determinedsequence may be applied to the airfoil 40 and an amount of variationfrom the initial geometry may be measured. The new geometry may bedesigned to compensate for the measured amount of variation from theinitial geometry. The new geometry may offset certain dimensions toaccount for distortion produced by application of LSP on the airfoil.

For example, if application of the determined sequence for LSP resultedin a greater amount of lean in one direction (from the initial, i.e.blueprint, geometry), then the new geometry would compensate for thisdistortion by offsetting its lean from the initial geometry in the otherdirection by the measured amount of variation. In another example, ifapplication of the determined sequence for LSP resulted in a greateramount of twist, then the new geometry would account for this distortionby having a lesser amount of twist in the measured amount of variationfrom the initial geometry. Distortions in other geometric dimensions,such as, including but not limited to thickness, chord length, andcamber, may also be accounted for in the new geometry. Thus, the newgeometry may compensate for the variation in an opposite direction andequal magnitude from the initial geometry.

Next, at a step 80, a new airfoil may be provided according to the newgeometry. Lastly, at a step 82 the sequence from step 76 may be appliedon the new airfoil having the new geometry. As a result of thedistortion being compensated for in the new geometry in step 78, whenthe determined sequence for the applications of LSP is provided in step82, the geometry of the new airfoil may be substantially identical tothe initial or blueprint geometry for the airfoil, measured in step 72.In so doing, an initial or blueprint geometry for the airfoil may beachieved, effectually having no distortion.

It is to be understood that other steps in the manufacturing method 70may be added, such as finishing, without departing from the scope of thedisclosure. In addition to sequencing the applications, an intensity ofthe applications may also be varied from the first side 42 to the secondside 44 to minimize or eliminate distortion. Furthermore, althoughdescribed as applying to an airfoil of the gas turbine engine, thedisclosed methods 30, 50, 70 may certainly be applied to othercomponents of the gas turbine engine, as well as non-engine relatedcomponents.

INDUSTRIAL APPLICABILITY

From the foregoing, it can be seen that the teachings of this disclosurecan find industrial application in any number of different situations,including but not limited to, gas turbine engines. Such engines may beused, for example, on aircraft for generating thrust, or in land,marine, or aircraft applications for generating power.

The present disclosure provides a method to minimize the distortion inparts due to material improvement processes. By sequencing theapplications of LSP, the total distortion of the part can be eliminatedor minimized. In addition, sequencing applications can reduce the extentof antagonistic stresses in an airfoil, thereby resulting in a morerobust part. Furthermore, the disclosed methods may be applied to newand used parts to extend the life of the part, thereby reducing overallmaintenance costs.

While the foregoing detailed description has been given and providedwith respect to certain specific embodiments, it is to be understoodthat the scope of the disclosure should not be limited to suchembodiments, but that the same are provided simply for enablement andbest mode purposes. The breadth and spirit of the present disclosure isbroader than the embodiments specifically disclosed, but rather includesall embodiments and equivalents encompassed within the claims appendedhereto as well.

What is claimed is:
 1. A method for laser shock peening (LSP) aworkpiece, comprising: identifying a geometry of the workpiece;determining a number of non-simultaneous applications of LSP upon afirst side and a second side of the workpiece; and sequencing thenon-simultaneous applications among the first side and the second sideto minimize distortion, wherein each non-simultaneous application of LSPon the first side occurs at a different time than each non-simultaneousapplication of LSP on the second side.
 2. The method of claim 1, furthercomprising providing one application to the first side of the workpiece,and measuring a change in geometry of the workpiece.
 3. The method ofclaim 1, further comprising providing one application to the second sideof the workpiece, and measuring a change in geometry of the workpiece.4. The method of claim 1, further comprising determining which side ofthe workpiece to provide a first application of LSP.
 5. The method ofclaim 1, further comprising determining a sequence of thenon-simultaneous applications based on measured changes in geometry ofthe workpiece after each successive application.
 6. The method of claim1, further comprising using a coordinate measuring machine (CMM) tomeasure the geometry of the workpiece.
 7. A method for laser shockpeening (LSP) an airfoil, comprising: identifying an initial geometry ofthe airfoil; determining a number of non-simultaneous applications ofLSP upon each of a first side and a second side of the airfoil; andproviding the non-simultaneous applications in a sequence having aminimum amount of variation from the initial geometry of the airfoil,wherein each non-simultaneous application of LSP on the first sideoccurs at a different time than each non-simultaneous application of LSPon the second side.
 8. The method of claim 7, further comprising furthercomprising providing three non-simultaneous applications to each of thefirst side and the second side of the airfoil.
 9. The method of claim 7,further comprising determining the sequence based on an amount ofvariation from the initial geometry of the airfoil after eachapplication.
 10. The method of claim 7, further comprising providing thesequence as a first application to the first side, a second applicationto the second side, a third application to the second side, a fourthapplication to the first side, a fifth application to the first side,and a sixth application to the second side.
 11. A method formanufacturing an airfoil of a gas turbine engine, comprising: measuringan initial geometry of the airfoil; determining a number ofnon-simultaneous applications of laser shock peening to provide on theairfoil; determining a sequence for the non-simultaneous applications,wherein each non-simultaneous application of LSP on the first sideoccurs at a different time than each non-simultaneous application of LSPon the second side; determining a new geometry for the airfoil based onthe initial geometry and the sequence; providing an airfoil according tothe new geometry; and applying the sequence on the airfoil having thenew geometry.
 12. The method of claim 11, further comprising measuringthe initial geometry of the airfoil, including at least one ofthickness, chord length, camber, twist, and lean.
 13. The method ofclaim 11, further comprising providing a first application to a pressureside of the airfoil.
 14. The method of claim 13, further comprisingproviding a second application to a suction side, a third application tothe suction side, a fourth application to the pressure side, a fifthapplication to the pressure side, and a sixth application to the suctionside.
 15. The method of claim 11, further comprising providingnon-simultaneous applications to the pressure and suction sides of theairfoil and measuring variations in geometry to determine the sequence.16. The method of claim 15, further comprising determining the sequencebased on a sequence having a smallest amount of variation in geometry.17. The method of claim 16, further comprising applying the sequence toan airfoil having the initial geometry.
 18. The method of claim 17,further comprising measuring an amount of variation in geometry from theinitial geometry after applying the sequence.
 19. The method of claim18, further comprising designing the new geometry of the airfoil tocompensate for the measured amount of variation in geometry.
 20. Themethod of claim 19, further comprising compensating for the measuredamount of variation in geometry by offsetting a lean and a twist in thenew geometry of the airfoil.